Motion Behavior and Welding Performance of Weakly Conductive and Difficultly Deformed Metal Electromagnetic Pulse Welding Based on Dual-Coil and Dual-Drive
Li Chengxiang1, Chen Dan1, Wu Zhaoxiao1, Shu Yihang1, Zhou Yan1,2
1. State Key Laboratory of Power Transmission Equipment Technology Chongqing University Chongqing 400044 China; 2. School of Electronics and IoT Chongqing Polytechnic University of Electronic Technology Chongqing 401331 China
Abstract：Electromagnetic pulse welding (EMPW) achieves metallurgical bonding by utilizing electromagnetic forces induced in metal workpieces to drive their high-speed deformation and collision. However, for weakly conductive and difficultly deformed metals, such as zirconium alloy and stainless-steel, the use of a single driver has been proved to be inadequate for achieving bonding. Therefore, a novel EMPW method based on dual-coil and dual-drive was proposed, whose feasibility is validated through theoretical analysis, simulation, and experiment. T2 copper plates were served as driver plates, while Zr-3 zirconium alloy plates and 304 stainless-steel plates were the workpieces to be welded. By analyzing the motion dynamics of the plates during both single-drive and dual-drive welding processes, as well as the relationship between driver plate thickness and skin depth, it was determined that the electromagnetic force induced in the driver plate must overcome not only its own deformation resistance but also that of the workpieces being welded. A simulation model for zirconium alloy and stainless-steel plates EMPW was established in COMSOL software. In dual-drive EMPW, the zirconium alloy and stainless-steel plates exhibited negligible induced eddy currents due to the shielding effect of the copper drive board. The dual-drive welding method demonstrated a smaller magnetic flux density while achieving higher induced eddy current density and electromagnetic force density. The electromagnetic force generated during single-drive welding method was insufficient to induce a collision between the zirconium alloy and stainless-steel plates, resulting in inferior welding performance compared to dual-drive welding method. An EMPW experimental platform for zirconium alloy and stainless-steel plates was established. Welding experiments were conducted using an asymmetrical dual H-typed coil. Welding experiments were conducted under a discharge voltage of 11, 12, 13 and 14 kV using both single-drive and dual-drive methods. Metallurgical bonding could not be achieved with the single-drive approach, whereas successful bonding was realized with the dual-drive method. The tensile test results showed that the tensile strength of the joint is higher than that of the zirconium alloy base material. Scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analyses revealed distinct wavy patterns at the bonding interface, with elemental diffusion and mechanical interlocking identified as the primary bonding mechanism. The following conclusions can be drawn from theory, simulation and experiments: (1) The specific situation for selecting the EMPW method based on dual-coil and dual-drive has been determined. The dual-drive welding method for weakly conductive and difficultly deformed metals can improve energy utilization efficiency. (2) Compared to single-drive welding, dual-drive welding exhibits a smaller magnetic flux density but achieves higher induced eddy current density and electromagnetic force density, enabling faster movement of the zirconium alloy and stainless-steel plates. (3) Under the conditions of this study, the primary bonding mechanism in dual-coil and dual-drive EMPW for zirconium alloy and stainless-steel plates is elemental diffusion and mechanical interlocking, and the joint tensile strength exceeds that of the base material itself.
李成祥, 陈丹, 吴赵骁, 舒一航, 周言. 基于双线圈双驱动的弱导电性难变形金属电磁脉冲焊接运动行为与焊接性能[J]. 电工技术学报, 2026, 41(9): 2914-2925.
Li Chengxiang, Chen Dan, Wu Zhaoxiao, Shu Yihang, Zhou Yan. Motion Behavior and Welding Performance of Weakly Conductive and Difficultly Deformed Metal Electromagnetic Pulse Welding Based on Dual-Coil and Dual-Drive. Transactions of China Electrotechnical Society, 2026, 41(9): 2914-2925.
[1] 江进波, 赵鑫, 程廷强, 等. 基于场路耦合的磁开关优化设计方法研究[J/OL]. 高压电器, 2024: 1-9[2025-04-01]. https://kns.cnki.net/kcms/detail/61.1127. TM.20241028.1651.002.html. Jiang Jinbo, Zhao Xin, Cheng Tingqiang, et al. Research on the optimization design method of magnetic switch based on field-circuit coupling[J/OL]. High Voltage Apparatus, 2024: 1-9[2025-04-01]. https://kns.cnki.net/kcms/detail/61.1127.TM.20241028.1651.002.html. [2] 周言, 李成祥, 杜建, 等. 放电电压对镁-铝磁脉冲焊接中金属射流及结合界面的影响[J]. 电工技术学报, 2022, 37(2): 459-468, 495. Zhou Yan, Li Chengxiang, Du Jian, et al.Investigation on the effect of discharge voltage on metal jet and bonded interface in Mg-Al magnetic pulse welding[J]. Transactions of China Electrotechnical Society, 2022, 37(2): 459-468, 495. [3] 李成祥, 王现民, 周言, 等. 基于双线圈结构的铝-铜电磁脉冲板件焊接中间层抑制方法[J]. 电工技术学报, 2025, 40(13): 4112-4124. Li Chengxiang, Wang Xianmin, Zhou Yan, et al.The suppression of intermediate layer in Al-Cu electromagnetic pulse welding with double coils structure[J]. Transactions of China Electrotechnical Society, 2025, 40(13): 4112-4124. [4] Wang Xianmin, Li Chengxiang, Zhou Yan, et al.Electromagnetic-mechanical response mechanism and microstructure evolution during Al-Mg electromagnetic pulse welding[J]. Materials Characterization, 2024, 215: 114174. [5] Ayaz M, Khandaei M, Vahidshad Y.Optimizing the mechanical properties of Al-SS joint using the numerical and experimental investigation of electromagnetic welding[J]. Journal of Adhesion Science and Technology, 2021, 35(20): 2202-2229. [6] Xie Jilin, Chen Yuhua, Wang Hongwei, et al.Phase transformation mechanisms of NiTi shape memory alloy during electromagnetic pulse welding of Al/ NiTi dissimilar joints[J]. Materials Science and Engineering: A, 2024, 893: 146119. [7] Zittel G.A historical review of high speed metal forming[C]//4th International Conference on High Speed Forming, Columbus, Ohio, USA, 2010: 2-15. [8] 李成祥, 杜建, 陈丹, 等. 基于电磁脉冲成形技术的电缆接头压接装置的研制及实验研究[J]. 高电压技术, 2020, 46(8): 2941-2950. Li Chengxiang, Du Jian, Chen Dan, et al.Develo-pment and experimental study of cable joint pressure connecting device based on the electromagnetic pulse forming technology[J]. High Voltage Engineering, 2020, 46(8): 2941-2950. [9] Li Chengxiang, Shen Ting, Zhou Yan, et al.EMPC of aluminium wire and copper terminal for electric vehicles[J]. Materials and Manufacturing Processes, 2023, 38(3): 306-313. [10] 李成祥, 陈丹, 周言, 等. 电磁脉冲焊接锂离子电池叠层极耳电磁力分布及运动特性[J]. 高电压技术, 2025, 51(1): 412-422. Li Chengxiang, Chen Dan, Zhou Yan, et al.Electromagnetic parameters distribution and tabs motion characteristic of electromagnetic pulse welding for lithium-ion battery laminated tabs[J]. High Voltage Engineering, 2025, 51(1): 412-422. [11] Raoelison R N, Li J S, Sapanathan T, et al.Gradient of nanostructures at the interface of Al/Cu welded joints produced by the high strain-rate collision during magnetic pulse impact welding[J]. Journal of Alloys and Metallurgical Systems, 2024, 5: 100060. [12] Bembalge O B, Singh B, Panigrahi S K.Magnetic pulse welding of AA6061 and AISI 1020 steel tubes: Numerical and experimental investigation[J]. Journal of Manufacturing Processes, 2023, 101: 128-140. [13] Wang Pengfei, Ning Xing, Du Jian, et al.Electromagnetic pulse welding on a magnesium-aluminum joint: role of angle of welding[J]. Materials and Manufacturing Processes, 2023, 38(4): 371-378. [14] Patra S, Arora K S, Shome M, et al.Interface characteristics and performance of magnetic pulse welded copper-steel tubes[J]. Journal of Materials Processing Technology, 2017, 245: 278-286. [15] Shotri R, Faes K, De A.Magnetic pulse welding of copper to steel tubes-experimental investigation and process modelling[J]. Journal of Manufacturing Processes, 2020, 58: 249-258. [16] 张望, 朱鑫辉, 邱立, 等. 基于铜环驱动的TA2钛板电磁成形数值模拟与实验研究[J]. 电工技术学报, 2025, 40(11): 3339-3348. Zhang Wang, Zhu Xinhui, Qiu Li, et al.Numerical and experimental study of electromagnetic drive forming for TA2 titanium sheet based on a copper ring[J]. Transactions of China Electrotechnical Society, 2025, 40(11): 3339-3348. [17] Sharma S K, Aravind J M V V S, Mishra S, et al. Magnetic pulse welding of thin walled ferritic martensitic steel T91 tube to T91 rod[J]. Materials Today: Proceedings, 2023, 87: 115-121. [18] Kumar S, Khan M R, Saroj P C, et al.Experimental investigation of driver material on electromagnetic welding of alloy D9 SS tube to SS316L(N) plug[J]. The International Journal of Advanced Manufacturing Technology, 2019, 105(10): 4225-4235. [19] Mishra S, Aravind J, Sharma S K.Titanium to SS-304 dissimilar metal joints by magnetic pulse welding[J]. BARC Newsletter, 2022(3-4): 37-40. [20] Aizawa T, Okagawa K, Kashani M.Application of magnetic pulse welding technique for flexible printed circuit boards (FPCB) lap joints[J]. Journal of Materials Processing Technology, 2013, 213(7): 1095-1102. [21] Ayaz M, Khandaei M, Vahidshad Y.Investigating the effect of electromagnetic impact welding parameters on the microstructure evolution and mechanical properties of SS-Cu joint[J]. Materials Today Communications, 2023, 35: 105404. [22] Wang Kuaishe, Wu Bing, Qiao Ke, et al.Microstructure and mechanical properties of friction stir lap welded dissimilar zirconium-steel joint[J]. Journal of Materials Research and Technology, 2020, 9(6): 15087-15093. [23] 熊奇, 陈开创, 马朝杰, 等. 多边形金属板件洛伦兹力驱动冲压成形动态过程分析及成形效果优化[J]. 电工技术学报, 2025, 40(7): 2007-2019. Xiong Qi, Chen Kaichuang, Ma Chaojie, et al.Dynamic process analysis and optimization of forming effects in Lorentz force stamping for polygonal sheet metal[J]. Transactions of China Electrotechnical Society, 2025, 40(7): 2007-2019. [24] 李成祥, 杜建, 周言, 等. 电磁脉冲板件焊接设备研制及镁/铝合金板焊接实验研究[J]. 电工技术学报, 2021, 36(10): 2018-2027. Li Chengxiang, Du Jian, Zhou Yan, et al.Development of electromagnetic pulse welding equipment for plates and experimental research on magnesium/aluminum alloy welding[J]. Transactions of China Electrotech-nical Society, 2021, 36(10): 2018-2027. [25] 熊奇, 邱爽, 李彦昕, 等. 组合式电磁成形技术研究进展[J]. 电工技术学报, 2024, 39(9): 2710-2729. Xiong Qi, Qiu Shuang, Li Yanxin, et al.Research progress of combined electromagnetic forming technology[J]. Transactions of China Electrotechnical Society, 2024, 39(9): 2710-2729. [26] Zhou Yan, Li Chengxiang, Shi Xin, et al.Evaluation model of electromagnetic pulse welding effect based on Vc-β trajectory curve[J]. Journal of Materials Research and Technology, 2022, 20: 616-626. [27] 熊奇, 马朝杰, 阎诺, 等. 应用于电磁脉冲焊接的倒梯形截面H型线圈[J]. 电工技术学报, 2025, 40(20): 6422-6432. Xiong Qi, Ma Chaojie, Yan Nuo, et al.Inverted trapezoidal cross-section H-shaped coil for electro-magnetic pulse welding[J]. Transactions of China Electrotechnical Society, 2025, 40(20): 6422-6432. [28] Zhou Yan, Li Chengxiang, Shi Xin, et al.Effect of DH-shaped coil symmetry coefficient on EMPW process[J]. Materials and Manufacturing Processes, 2024, 39(8): 1122-1130. [29] 李成祥, 石鑫, 周言, 等. 针对H型线圈的电磁脉冲焊接仿真及线圈截面结构影响分析[J]. 电工技术学报, 2021, 36(23): 4992-5001. Li Chengxiang, Shi Xin, Zhou Yan, et al.Electromagnetic pulse welding simulation for H-type coil and analysis of the influence of coil cross-sectional structure[J]. Transactions of China Electrotechnical Society, 2021, 36(23): 4992-5001. [30] Li Chengxiang, Zhou Yan, Shi Xin, et al.Magnetic field edge-effect affecting joint macro-morphology in sheet electromagnetic pulse welding[J]. Materials and Manufacturing Processes, 2020, 35(9): 1040-1050.
2026, Vol. 41 
